Progress on study of key technologies for polymethacrylimide foam core sandwich lifecycle
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摘要: 聚甲基丙烯酰亚胺(Polymethylimide，PMI)泡沫夹层结构特有的性能优势使其广泛应用于航空航天领域。为推动PMI泡沫夹层结构的稳定化、系列化和高性能化，本文系统地综述了面向全生命周期的PMI泡沫夹层结构设计与制造技术的研究现状与发展趋势。首先，总结了PMI泡沫及其夹层结构的性能和应用现状，分析了PMI泡沫夹层结构的市场需求。然后，概述了面向全生命周期的PMI泡沫夹层结构关键技术现状，包括PMI泡沫研发、结构设计与分析、结构固化成型、维修及维护。最后，展望了PMI泡沫夹层结构的发展趋势，以期为该领域后续的研究工作提供参考。Abstract: Polymethylimide (PMI) foam core sandwich has unique performance advantages, which leads to a wide application in aerospace structures. In order to promote the stabilization, serialization and high performance for PMI foam core sandwich, the present research situation and development trend of PMI foam core sandwich design and manufacturing technology for lifecycle were systematically reviewed. Firstly, the performance and application situation of PMI foam and its core sandwich were summarized, and the market demand of PMI foam core sandwich was analyzed. Then, the key technologies situations of PMI foam core sandwich lifecycle were curtly described, including the research of PMI foam, structure design and analysis, structure curing and forming, repair and maintenance, etc. Finally, the development trend of PMI foam core sandwich was prospected, so that to provide reference for further research.
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Key words:
- polymethacrylimide /
- sandwich /
- composites /
- design /
- manufacture /
- maintenance
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图 5 具有冲击损伤的复合材料泡沫夹层结构有限元模型
Figure 5. Finite element model of the composite foam core sandwich structure with impact damage
图 7 复合材料泡沫夹层结构和等效间隔板高速冲击能量吸收
Figure 7. Energy absorbed of composite foam core sandwich structure and spaced plates with high impact velocity
图 10 复合材料泡沫夹层结构共固化成型示意图
Figure 10. Co-curing molding diagram of composite foam core sandwich structure
图 11 分步固化成型制备的PMI泡沫夹层结构机翼示意图
Figure 11. Diagram of PMI foam core sandwich structure wing prepared by step curing molding
表 1 聚甲基丙烯酰亚胺(PMI)泡沫夹层结构的应用现状[1, 7-10]
Table 1. Application status of polymethylimide (PMI) foam core sandwich[1, 7-10]
Field Structure Proportion Application example Legend demonstration Fixed wingaircraft Fuselage, wing, tail and floor 80% MD11, Airbus A320/A340/A380, C-17, ATR 72, Dornier 728,Embraer 145, ARJ21, C919 
Helicopter Paddle, floor, fairing, hatch, water drip, side vertical tail, engine hood "Dolphin", "SM", "King of the sea", EC135, NH90, "Tiger" helicopter, LE100 
Rocket Cowling, cryogenic tank Delta carrier rocket, Hll-a carrier rocket, Long 3A series carrier rocket 
Traffic Locomotive, ship superstructure, upper deck and bulkhead 15% E4 Shinkansen, New generation maglev train of CRRC Zhuzhou Electric Locomotive Co. Ltd., Ships manufactured by Kvarner mandal 
Sports, medical treatment, power generation, communication Bicycle frame, CT scanning bed plate, wind turbine blade, car body 5% Medical X-ray full body CT scanners of general motors, Siemens, et al, Wind turbine blades of Vestas, Ferrari formula one body structure, New generation bicycles 
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表 2 PMI泡沫力学性能指标和测试方法
Table 2. Mechanical properties and test methods of PMI foam
Foam mechanical property Evaluation index Test method Tensile strength and modulus X3、X4、X7 ASTM D638[24] Compressive strength and modulus X3、X5、X8 ASTM D1621[25] Bending strength and modulus X2、X3 ASTM D790[26] Shear strength and modulus X1-X7 ASTM C273[27] Fatigue strength X4、X6、X7 ASTM C394[28] Thermal deformation temperature X8 ASTM D648[29] Moisture absorption X9、X10 ASTM C272[30] Aging X11 ASTM C481[31]
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表 3 PMI泡沫蜂窝夹芯结构的弯曲试验数据[33]
Table 3. Bending test data of sandwich structures between PMI foam and honeycomb cores[33]
Failure detail Honeycomb core Rohacell 71 foam core Failure load/N 2 541+2 541 3 947+3 947 Deformation/mm 58.34 17.33 Failure type Permanent set (8 mm) Failure at bond and core shear
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Sandwich Impact energy/J Maximum load/KN Initial damage load/KN Initial damage energy/J PMI 19.90 1.78 1.78 7.64 PVC 19.70 1.53 1.51 8.70 NOMEX 19.47 1.52 1.49 5.43 Note: PVC—Polyvinyl chloride.
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表 5 复合材料泡沫夹层结构固化方法对比
Table 5. Comparison of curing method of composite foam core sandwich structure
Method Process characteristic Autoclave molding Uniform distribution of pressure and temperature, low internal void ratio, simple mold, suitable for complex parts, high technical requirements for process personnel, high cost of autoclave Resin transfer molding Good surface quality, low porosity, high fiber density, overall integrity, suitable for medium batch production, complex mold manufacturing Resin film infusion Short process flow, fiber easy to be soaked, high fiber content, low porosity, excellent mechanical properties, good product reproducibility Vacuum assisted resin infusion Single side mold, low degree of mechanization and automation, long production cycle, low production cost, high resin requirements, low molding and curing pressure, suitable for large parts Compression molding High dimensional accuracy, high efficiency, high mold requirements, strict process control
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表 6 PMI泡沫夹层结构的维修方法对比
Table 6. Comparison of maintenance methods for PMI foam core sandwich structure
Method Process Failure mode Filling method First remove the surface damage, then carry out layer repair, and finally cure Surface damage Perfusion method First drill the glue injection hole and overflow hole, prepare the glue, then inject the glue until the glue overflows from the overflow holes around Debonding damage Inlay method Including inclined excavation repair and ladder repair. The laying parameters of patch are consistent with those of mother board. Add 1-2 layers of patches to the final surface Panel damage,Core damage Flush repair Same as inlay. The difference is that the backing plate should be placed under the panel Holistic destruction,Core damage
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